Curved Glass Molding with Elastic Mold Alignment
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Solution Overview
Problem
Current glass molding methods face challenges in achieving high precision and efficiency, particularly when processing large curved glass, due to mold damage from repetitive use, weight-induced glass breakage, and increased nitrogen gas supply requirements.
Innovation Solution
A method involving a sequential stacking of molds and chambers with temperature control, using an elastic member to prevent mold damage and reduce nitrogen gas usage, and a transferring bar system to minimize impact and optimize nitrogen use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If press molding method is used to achieve high molding precision, then molding precision is improved, but mold damage occurs due to repetitive use
Solution Approach 1:
The mold is divided into an upper mold and a lower mold that can be separated. The upper mold is removable and can be taken out for cleaning and maintenance without damaging the lower mold or the glass product. This segmentation allows the upper mold to be periodically serviced while maintaining the precision of the lower mold structure.
Solution Approach 2:
The glass plate is pre-heated to a specific temperature range (softening point to melting point) before the molding process. This preliminary heating prepares the glass to be more pliable and less prone to damage during molding, reducing the impact forces that would otherwise damage the mold through repetitive use.
2Productivity
If upper mold is pressurized to mold glass, then molding process is completed, but glass breaks due to weight of upper mold
Solution Approach 1:
The upper mold is designed with a pressing mechanism that applies controlled, progressive pressure rather than static weight. The pressing force can be dynamically adjusted during the molding process to match the glass's changing viscosity and structural integrity, preventing breakage while completing the molding.
Solution Approach 2:
A pressing mechanism acts as an intermediary between the upper mold and the glass plate. This mechanism distributes the molding force evenly across the glass surface, preventing localized stress concentrations that would cause breakage, while still achieving the necessary molding pressure.
3Reliability
If nitrogen gas is supplied to prevent oxidization, then mold protection is improved, but processing time increases
Solution Approach 1:
Instead of continuous nitrogen gas supply, the system uses periodic or on-demand nitrogen supply. Nitrogen is supplied only when needed during critical oxidation-prone phases of the molding process, and the upper mold can be removed for cleaning without requiring continuous nitrogen atmosphere, thereby reducing overall processing time.
Solution Approach 2:
The upper mold is designed to be removable and extractable from the lower mold. This allows the upper mold to be taken out for cleaning and maintenance without requiring prolonged nitrogen gas supply, reducing the total time nitrogen must be supplied and thereby shortening the overall processing time while still protecting the mold from oxidation during the molding process.
4Area of stationary object
If large glass is processed, then display application is enabled, but molding precision deteriorates
Solution Approach 1:
The mold assembly is segmented into separable upper and lower molds with precise alignment mechanisms. This segmentation allows for better control of large glass plates during molding, as each mold component can be independently positioned and secured, maintaining precision even as the overall glass size increases.
Solution Approach 2:
The glass plate undergoes preliminary heating to a controlled temperature range before molding. This pre-heating process prepares the large glass plate to be more uniform in its physical properties, reducing warping and improving molding precision across the entire large surface area.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enhances molding precision, reduces mold damage, and shortens processing time while minimizing nitrogen gas consumption, thereby improving the efficiency and cost-effectiveness of curved glass production.
Implementation Method 1
An elastic member may be disposed between the lower mold and the upper mold so that the upper mold is spaced apart from the flat glass, and may be compressed when the upper mold is pressurized.
Implementation Method 2
a second step of moving the mold assembly to a first chamber and heating the mold assembly
Implementation Method 3
a fourth step of moving the mold assembly from the second chamber to a third chamber and then slowly cooling the molded glass
Data Source
Figure 1
Figure 2A~2B
Figure 3A
AI summary
The present invention relates to a curved glass manufacturing method. The present invention provides a curved glass manufacturing method comprising: a first step of successively stacking a lower mold, flat glass, and an upper mold, thereby forming a mold assembly; a second step of moving the mold assembly to a first chamber and then heating the same; a third step of moving the mold assembly from the first chamber to a second chamber and then pressurizing the upper mold so as to move the upper mold downward, thereby molding the flat glass in a curved shape; a fourth step of moving the mold assembly from the second chamber to a third chamber and then slowly cooling the molded glass; and a fifth step of moving the mold assembly from the third chamber to a fourth chamber and then cooling the molded glass. The curved glass manufacturing method is characterized in that an elastic member is arranged between the lower mold and the upper mold so as to move the upper mold away from the flat glass, and the elastic member is compressed when the upper mold is pressurized.